Wire-feed laser additive manufacturing of dissimilar metals via dual molten pool interface interlocking mechanism

Intermetallic compounds produced in laser additive manufacturing are the main factors restricting the joint performance of dissimilar metals.To solve this problem,a dual molten pool interface interlocking mechanism was proposed in this study.Based on a dual molten pool interface interlocking mechanism,the dissimilar metals,aluminum alloy and stainless steel,were produced as single-layer and multilayer samples,using the wire-feed laser additive manufacturing directed energy deposition technology.The preferred parameters for the dual molten pool interface interlocking mechanism process of the dissimilar metals,aluminum alloy and stainless steel,were obtained.The matching relationship between the interface connection of dissimilar metals and the process parameters was established.The results demonstrated excellent mechanical occlusion at the connection interface and no apparent intermetallic compound layer.Good feature size and high microhardness were observed under a laser power of 660 W,a wire feeding speed of 55 mm/s,and a platform moving speed of 10 mm/s.Molecular dynamics simulations demonstrated a faster rate of aluminum diffusion in the aluminum alloy substrate to stainless steel under the action of the initial contact force than without the initial contact force.Thus,the dual molten pool interface interlocking mechanism can effectively reduce the intermetallic compound layer when dissimilar metals are connected in the aerospace field.

Investigation on Reaction Interface between the Aluminum and K2ZrF6 by Freezing the Molten Salt Reaction

A reaction interface between the aluminum and K_2ZrF_6 during molten salt reaction process was frozen by quenching the mold in water, and the interface structure was analyzed to determine the formation process of Al_3Zr. Results show that a clear conical interface existed between the K_2ZrF_6 and aluminum. A zirconium accumulation layer with the thickness of about 2–3 lm was formed at the aluminum side of the interface. Many initially formed Al_3Zr particles（with the size of 0.4–16 lm） distributed in this layer, most of which located at the interface. The morphology of Al_3Zr particles is closely related with their size. For the size of 0.4–1 lm, the Al_3Zr appeared as globular and ellipsoid shapes. When it grew to the size of 1–2 and 2–16 lm, it exhibited the rule cube shape, and rule cuboids shape, respectively.